Collection of papers from the "Reliability & Robust Design in Automotive Engineering" session of the SAE 2006 World Congress, held April 3-6 in Detroit, Michigan.

Vehicle reliability problems continue to be the news because of major vehicle recalls from several manufacturers. This book includes 40 SAE technical papers, published from 2007 through 2010, that describe the latest research on automotive electronics reliability technology. This book will help engineers and researchers focus on the design strategies being used to minimize electronics reliability problems, and how to test and verify those strategies. After an overview of durability, risk assessment, and failure mechanisms, this book focuses on state-of-the-art techniques for reliability-based design, and reliability testing and verification. Topics include: powertrain control monitoring distributed automotive embedded systems model-based design x-by-wire systems battery durability design verification fault tree analysis The book also includes editor Ronald K. Jurgen’s introduction ,“Striving for Maximum Reliability in a Highly Complex Electronic Environment”, and a concluding section on the future of electronics reliability, including networking technology, domain control units, the use of AUTOSAR, and embedded software.

Learn how ART and ADT can reduce cost, time, product recalls, and customer complaints This book provides engineers with the techniques and tools they need to use accelerated reliability testing (ART) and accelerated durability testing (ADT) as key factors to accurately predict a product's quality, reliability, durability, and maintainability during a given time, such as service life or warranty period. It covers new ideas and offers a unique approach to accurate simulation and integration of field inputs, safety, and human factors, as well as accelerated product development, as components of interdisciplinary systems engineering. Beginning with a comprehensive introduction to the subject of ART and ADT, the book covers: ART and ADT as components of an interdisciplinary systems of systems approach Methodology of ART and ADT performance Equipment for ART and ADT technology ART and ADT as sources of initial information for accurate quality, reliability, maintainability, and durability prediction and product accelerated development The economical results of the usage of ART and ADT ART and ADT standardization The book covers the newest techniques in the field and provides many case studies that illuminate how the implementation of ART and ADT can solve previously inaccessible problems in the field of engineering, such as reducing product recalls, cost, and time during design, manufacture, and usage. Professionals will find the answers to how one can carry out ART and ADT technology in a practical manner. Accelerated Reliability and Durability Testing Technology is indispensable reading for engineers, researchers in industry, usage, and academia who are involved in the design of experiments, field simulations, maintenance, reliabilty, durabilty, accurate prediction, and product development, and graduate students in related courses.

Based on deep theoretical as well as practical experience in Reliability and Quality Sciences, Robust Design Methodology for Reliability constructively addresses practical reliability problems. It offers a comprehensive design theory for reliability, utilizing robust design methodology and six sigma frameworks. In particular, the relation between un-reliability and variation and uncertainty is explored and reliability improvement measures in early product development stages are suggested. Many companies today utilise design for Six Sigma (DfSS) for strategic improvement of the design process, but often without explicitly describing the reliability perspective; this book explains how reliability design can relate to and work with DfSS and illustrates this with real–world problems. The contributors advocate designing for robustness, i.e. insensitivity to variation in the early stages of product design development. Methods for rational treatment of uncertainties in model assumptions are also presented. This book promotes a new approach to reliability thinking that addresses the design process and proneness to failure in the design phase via sensitivity to variation and uncertainty; includes contributions from both academics and industry practitioners with a broad scope of expertise, including quality science, mathematical statistics and reliability engineering; takes the innovative approach of promoting the study of variation and uncertainty as a basis for reliability work; includes case studies and illustrative examples that translate the theory into practice. Robust Design Methodology for Reliability provides a starting point for new thinking in practical reliability improvement work that will appeal to advanced designers and reliability specialists in academia and industry including fatigue engineers, product development and process/ quality professionals, especially those interested in and/ or using the DfSS framework.

This textbook reviews the methodologies of reliability prediction as currently used in industries such as electronics, automotive, aircraft, aerospace, off-highway, farm machinery, and others. It then discusses why these are not successful; and, presents methods developed by the authors for obtaining accurate information for successful prediction. The approach is founded on approaches that accurately duplicate the real world use of the product. Their approach is based on two fundamental components needed for successful reliability prediction; first, the methodology necessary; and, second, use of accelerated reliability and durability testing as a source of the necessary data. Applicable to all areas of engineering, this textbook details the newest techniques and tools to achieve successful reliabilityprediction and testing. It demonstrates practical examples of the implementation of the approaches described. This book is a tool for engineers, managers, researchers, in industry, teachers, and students. The reader will learn the importance of the interactions of the influencing factors and the interconnections of safety and human factors in product prediction and testing.

This book is aimed at readers who need to learn the latest solutions for interconnected simulation, testing, and prediction technologies that improve engineering product efficiency, including reliability, safety, quality, durability, maintainability, life-cycle costing and profit. It provides a detailed analysis of technologies now being used in industries such as electronics, automotive, aircraft, aerospace, off-highway, farm machinery, and others. It includes clear examples, charts, and illustrations. This book provides analyses of the simulation, testing, and prediction approaches and methodologies with descriptive, negative trends in their development. The author discusses why many current methods of simulation, testing, and prediction are not successful and describes novel techniques and tools developed for eliminating these problems. This book is a tool for engineers, managers, researches in industry, teachers, and students. Lev Klyatis, Hab. Dr.-Ing., ScD., PhD, Senior Advisor SoHaR, Inc., has been a professor at Moscow State Agricultural Engineering University, research leader and chairman of State Enterprise TESTMASH, and served on the US Technical Advisory Group for the International Electrotechnical Commission (IEC), the ISO/IEC Join Study Group in Safety Aspects of Risk Assessment, the United Nations European Economical Commission, and US-USSR Trade and Economic Council. He is presently a member of World Quality Council, the Elmer A. Sperry Board of Award, SAE International G-41 Reliability Committee, the Integrated Design and Manufacturing Committee and session chairman of SAE International World Congresses in Detroit since 2012. His vast experience and innovation enable him to create a new direction for the successful prediction of product efficiency during any given time, including accurate simulation of real-world conditions, accelerated reliability and durability testing technology, and reducing recalls. His approach has been verified in various industries, primarily automotive, farm machinery, aerospace, and aircraft industries. He has shared his new direction working as the seminar instructor and consultant to Ford, DaimlerChrysler, Nissan, Toyota, Jatko Ltd., Thermo King, Black an Dekker, NASA Research Centers, Karl Schenck, and many others. He holds over 30 patents worldwide and is the author of over 300 publications, including 15 books.

The ability to successfully predict industrial product performance during service life provides benefits for producers and users. This book addresses methods to improve product quality, reliability, and durability during the product life cycle, along with methods to avoid costs that can negatively impact profitability plans. The methods presented can be applied to reducing risk in the research and design processes and integration with manufacturing methods to successfully predict product performance. This approach incorporates components that are based on simulations in the laboratory. The results are combined with in-field testing to determine degradation parameters. These approaches result in improvements to product quality, performance, safety, profitability, and customer satisfaction. Among the methods of analyses included are: • Accelerated Reliability Testing (ART) • Accelerated Durability Testing (ADT) • system variability / input variability • engineering risk versus time and expense

Accelerated testing (most types of laboratory testing, proving ground testing, intensive field/flight testing, any experimental research) is increasingly a key component for predicting of product's/process performance. Trends in Development Accelerated Testing for Automotive and Aerospace Engineering provides a completely updated analysis of the current status of accelerated testing, including the basic general directions of testing (methods and equipment) development, how one needs to study real world conditions for their accurate simulation and successful accelerated testing, describes in details the role of accurate simulation in the development of automotive and aerospace engineering, shows that failures are most often found in the interconnections, step-by-step instructions and examples. This is the only book presently available that considers in detail both the positive and negative trends in testing development for prediction quality, reliability, safety, durability, maintainability, supportability, profit, and decreasing life-cycle cost, recalls, complaints and other performance components of the product. The author presents new ideas and offers a unique strategic approach to obtaining solutions which were not possible using earlier. His methodology has been widely implemented, continue to be adopted throughout the world, and leads to advance society through product improvement that can reduce loss of life, injuries, financial losses, and product recalls. It also covers new ideas in development positive and cost- effective trends in testing development, especially accelerated reliability and durability testing (ART/ADT), which includes integration accurate simulation of field/flight influences, safety, human factors, and leads to successful prediction of product performance during pre-design, design, manufacturing, and usage for the product's service life. Engineers, researchers, teachers and postgraduate/advanced students who are involved in automotive and aerospace engineering will find this a useful reference on how to apply the accelerated testing method to solve practical problems in these areas. Explains the similarities and differences between accelerated testing technologies used in automotive, aerospace, and other engineering fields Provides a step-by-step guide for the accurate physical simulation of field conditions for test subjects Includes case studies of accelerated testing in automotive and aerospace engineering

This book considers all aspects of performability engineering, providing a holistic view of the activities associated with a product throughout its entire life cycle of the product, as well as the cost of minimizing the environmental impact at each stage, while maximizing the performance. Building on the editor's previous Handbook of Performability Engineering, it explains how performability engineering provides us with a framework to consider both dependability and sustainability in the optimal design of products, systems and services, and explores the role of performability in energy and waste minimization, raw material selection, increased production volume, and many other areas of engineering and production. The book discusses a range of new ideas, concepts, disciplines, and applications in performability, including smart manufacturing and Industry 4.0; cyber-physical systems and artificial intelligence; digital transformation of railways; and asset management. Given its broad scope, it will appeal to researchers, academics, industrial practitioners and postgraduate students involved in manufacturing, engineering, and system and product development.